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EP4454852A1 - Table d'emballage pour la fabrication d'un adaptateur d'assemblage utilisé dans un procédé d'assemblage - Google Patents

Table d'emballage pour la fabrication d'un adaptateur d'assemblage utilisé dans un procédé d'assemblage Download PDF

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Publication number
EP4454852A1
EP4454852A1 EP23170528.6A EP23170528A EP4454852A1 EP 4454852 A1 EP4454852 A1 EP 4454852A1 EP 23170528 A EP23170528 A EP 23170528A EP 4454852 A1 EP4454852 A1 EP 4454852A1
Authority
EP
European Patent Office
Prior art keywords
joining
material layup
packing table
blade
mandrel
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP23170528.6A
Other languages
German (de)
English (en)
Inventor
Gabriele Chiesura
Simon Vestphael RUSSEK
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Siemens Gamesa Renewable Energy AS
Original Assignee
Siemens Gamesa Renewable Energy AS
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Siemens Gamesa Renewable Energy AS filed Critical Siemens Gamesa Renewable Energy AS
Priority to EP23170528.6A priority Critical patent/EP4454852A1/fr
Priority to PCT/EP2024/058336 priority patent/WO2024223204A1/fr
Publication of EP4454852A1 publication Critical patent/EP4454852A1/fr
Pending legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/30—Mounting, exchanging or centering
    • B29C33/301—Modular mould systems [MMS], i.e. moulds built up by stacking mould elements, e.g. plates, blocks, rods
    • B29C33/302—Assembling a large number of mould elements to constitute one cavity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/04—Making preforms by assembling preformed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/12—Moulds or cores; Details thereof or accessories therefor with incorporated means for positioning inserts, e.g. labels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/38—Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
    • B29C33/40—Plastics, e.g. foam or rubber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/44—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
    • B29C33/48—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles with means for collapsing or disassembling
    • B29C33/485—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles with means for collapsing or disassembling cores or mandrels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/56—Coatings, e.g. enameled or galvanised; Releasing, lubricating or separating agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/70—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/0025—Producing blades or the like, e.g. blades for turbines, propellers, or wings
    • B29D99/0028—Producing blades or the like, e.g. blades for turbines, propellers, or wings hollow blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2825/00—Use of polymers of vinyl-aromatic compounds or derivatives thereof as mould material
    • B29K2825/04—Polymers of styrene
    • B29K2825/06—PS, i.e. polystyrene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/08—Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
    • B29L2031/082—Blades, e.g. for helicopters
    • B29L2031/085—Wind turbine blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D1/00—Wind motors with rotation axis substantially parallel to the air flow entering the rotor 
    • F03D1/06—Rotors
    • F03D1/065—Rotors characterised by their construction elements
    • F03D1/0675—Rotors characterised by their construction elements of the blades
    • F03D1/0677—Longitudinally segmented blades; Connectors therefor
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

  • the present invention relates to a packing table for manufacturing of a joining adapter to be used in a method for joining an outboard blade section to an inboard blade section of a longitudinally split wind turbine blade and to a method for manufacturing of a joining adapter.
  • Wind turbine blades especially for offshore use, continuously increase in size with the evolvement of technology.
  • current blades can reach a root diameter of approximately 6m, a blade length of over 100 m while typical chord lengths can reach up to 8 m.
  • Wind turbine blades manufactured according to this approach can be split at certain span locations so that the finished blade comprises at least two blade sections.
  • WO 2020/244902 A1 discloses a method for manufacturing a wind turbine blade from at least two longitudinally split blade sections.
  • a joining adapter comprising a fiber layup is arranged inside the two blade sections between joining interfaces on either side so that it overlaps at least partially with both the first and the second blade section.
  • the blade sections are tapered on the inside, wherein the joining adapter is correspondingly tapered on the outside to mate with the inside tapered joining interfaces of the blade sections.
  • the joining region is tightly sealed with vacuum bags both on the outside and the inside of the blade and the joining region is evacuated.
  • a resin system is injected into the evacuated joining region. The resin system penetrates into the fiber structure of the fiber layup of the joining adapter and to adjacent fibers at the joining interfaces of both blade sections. The resin system then cures under an exothermic reaction.
  • WO 2021/073842 A1 discloses another method for assembling blade parts of a wind turbine blade, wherein the method includes a customization and/or custom selection of a suitable joining adapter based on the individual geometry of the joining interfaces of the first and second blade sections.
  • a packing table for manufacturing of a joining adapter to be used in a method for joining an outboard blade section to an inboard blade section of a longitudinally split wind turbine blade in a joining zone is provided.
  • the packing table comprises:
  • the dimensions - in particular its length - of the packing table in particular equal the dimensions of the joining adapter to be produced with it.
  • a total length of the packing table can reach up to 11m and a total width can reach up to 6m.
  • the packing table can be understood as a kind of lower mold as the shape of its material layup surface corresponds with the outer contour of the joining adapter to be produced with it.
  • the packing table is not a mold in the literal sense as it is not used for infusing the material layup provided on it with a curable resin.
  • the material layup placed on top of the material layup surface is an exclusively dry material layup that is only cast, respectively infused with a curable resin, when the joining adapter is used in the method for joining an outboard blade section to an in-board blade section of a longitudinally split wind turbine blade in a joining zone.
  • a typical wind turbine blade comprises two or more blade sections dividing the blade in a lengthwise direction.
  • a first one of the blade sections is an inboard blade section.
  • the inboard blade section comprises, for example, a root section connectable to the hub of the rotor.
  • a second one of the blade sections is an outboard blade section.
  • the outboard blade section comprises, for example, a blade tip.
  • the wind turbine blade may also comprise one or more further blade sections.
  • “longitudinally split” means that the wind turbine blade is split at a certain spanwise location.
  • a typical wind turbine blade is formed aerodynamically.
  • the wind turbine blade i.e. each of its blade sections, comprises a pressure side (upwind side) and a suction side (downwind side).
  • the pressure side and the suction side may be connected with each other at a leading edge and a trailing edge.
  • the pressure and suction sides and the leading and trailing edges define an interior cavity of the wind turbine blade.
  • the main dimensions of the wind turbine blade - profile thickness and chord length - decrease from hub to tip; or in other words: A typical wind turbine blade narrows from in-board to outboard. Therefore the inboard and outboard blade sections are not cylindrical in the joining zone but frusto-conical.
  • the material layup surface may comprise at least two tapering sections with the center plane in between, wherein the tapering sections taper axially outwardly from the center plane in opposing axial directions.
  • a first tapering section is arranged in the inboard portion of the material layup surface and a second tapering portion is arranged in the outboard portion of the material layup surface.
  • the at least two tapering sections of the material layup surface correspond to inversely tapering sections of the blade sections to be joined with the joining adapter.
  • the inboard and the outboard blade section to be joined with the joining adapter comprise outwardly tapered portions such that their outwardly tapered portions form an inner recess in that the joining adapter can be arranged.
  • the tapering section of the inboard portion of the material layup surface of the packing table corresponds to an inversely tapered section of the inboard blade section
  • the tapering section of the outboard portion of the material layup surface of the packing table corresponds to an inversely tapered section of the outboard blade section.
  • tapering is to be understood relatively to the intended final contour of the wind turbine blade on its inner side. Given that the wind turbine blade - as well as its in-board and outboard blade sections - decreases both in thickness and chord length from hub to tip, a structure that tapers relatively to the intended final contour of the wind turbine blade on its inner side may not be tapering when compared to an imaginary cylinder shell. "Tapering” therefore in particular has the meaning of tapering relatively to the frusto-conical shape of the inboard and outboard blade sections in the joining zone.
  • the (lower) material layup provided thereon will have its highest thickness axially around the center plane. In opposing axial directions facing away from the center plane the material thickness gradually decreases and will finally come down to only a single digit of layers at the terminal axial ends of the packing table.
  • the joining adapter that can be produced with the packing table according to the invention is explicitly adapted to connect the inboard and the outboard blade section from the inside. Joining longitudinally split blade sections from the inside under use of correspondingly tapering sections on the inside of the blade sections has the specific advantage that the outer surfaces of the blade sections can be finished prior to the joining process. In particular, there is no need for additional filling, coating and/or painting of the outer surface of the blade after the joining process.
  • the packing table may comprise at least one groove in the material layup surface.
  • the at least one groove can extend in a circumferential direction.
  • the at least one groove is adapted to receive a tensioning strap.
  • a circumferential direction in particular is a direction that extends in a plane oriented normally with respect to the longitudinal axis of the wind turbine blade.
  • the groove extends with a certain axial component, for example following a helical path.
  • the at least one groove serves as a receiving space for a tensioning strap to be arranged therein during production of the joining adapter.
  • the tensioning strap is arranged in the groove as the very first step of a method for manufacturing of a joining adapter using the packing table according to the invention, i.e. already before the material layup starts.
  • the at least one groove has a predefined depth that can be 3mm - 15mm, in particular 4mm -10mm.
  • a width of the at least one groove can range from 30mm to 100mm, in particular from 40mm to 80mm, depending on the type and load rating of the tensioning strap used in the manufacturing method.
  • the tensioning strap is in particular used to secure a lower material layup provided on the material layup surface of the packing table and an upper layup provided on a mandrel against the mandrel.
  • the packing table may comprise multiple grooves in the material layup surface, in particular extending in a circumferential direction.
  • the multiple grooves can be provided with a predefined axial spacing there between and are each adapted to receive a tensioning strap.
  • Providing more than one groove allows for a more equal force distribution over the length of the joining adapter to be produced with the packing table of the invention and further reduces the risk of unintentional dislocation and/or loss of components of the material layup.
  • the axial spacing between neighboring grooves can be 300mm - 700mm, in particular 400mm - 600mm.
  • the optimum spacing depends on the type and load rating of the straps on the one hand and on the other hand on the mechanical properties of the material layup, e.g. the type and amount of fiber mats used therein, the type and amount of core materials, the thickness of the material layup and whether the material layup if provided in dry or pre-cast form.
  • the packing table may comprise a plastic material, in particular a closed cell foam, in particular an expanded polystyrene.
  • the plastic material provides the three dimensionally shaped material layup surface.
  • the plastic material can be coated with a relatively harder surface coating, in particular comprising a polyurethane.
  • a plastic material in particular a closed cell foam like expanded polystyrene, has the advantage that it can be three dimensionally formed very easily and quickly.
  • the three dimensional forming can either be done manually, e.g. by means of a hot wire cutter, or by machining with CNC-machinery.
  • the downside to said materials is their relatively poor mechanical stability, in particular the low hardness. Therefore it is beneficial to provide a relatively harder coating layer on top so that the material layup surface of the packing table obtains a higher durability, in particular against abrasion.
  • the relatively harder surface coating can be in particular applied by means of spray coating.
  • the packing table can comprise or be made of other materials as well, e.g. certain metals, in particular steel.
  • the packing table can comprise at least two sidewalls forming a half-pipe shaped portion of the material layup surface.
  • the half-pipe shaped portion of the material layup surface is located both in the inboard and the outboard portion of the material layup surface and neighbors the center plane.
  • the sidewalls do not extend along the entire length of the packing table but only axially around the center plane. It is possible that opposing axial end sections of the packing table are sidewall-free. In other words, the axial end sections of the packing table may exhibit a material layup surface that is essentially flat.
  • the shape of the material layup surface may correspond to an inner contour of a portion of the respective joining sections of the blade sections to be joined that are associated with a suction side of the wind turbine blade.
  • the lower material layup of the joining adapter that is done on the packing table according to the invention relates to a suction side of the wind turbine blade
  • the upper material layup of the joining adapter that is done on the mandrel relates to a pressure side of the wind turbine blade.
  • the packing table may comprise a multitude of plates stacked in the axial direction, wherein each plate comprises a portion of the material layup surface so that the material layup surface is provided by a totality of stacked plates.
  • the thickness of the plates may be between 0,2 and 1,5 m, preferably between 0,3 and 0,8 m.
  • the packing table may have a modular design what is advantageous as it renders the three dimensional shaping of the material layup surface easier as the individual plates with a limited thickness can be processed with less effort.
  • a method for manufacturing of a joining adapter to be used in a method for joining an outboard blade section to an inboard blade section of a longitudinally split wind turbine blade in a joining zone, using a packing table according to the invention is proposed.
  • the method comprises the steps of:
  • the final outer contour of the joining adapter is generated.
  • the inboard portion of the material layup surface shapes a portion of the joining adapter that corresponds with an inner contour of the joining interface of the inboard blade section and the outboard portion of the material layup surface shapes a portion of the joining adapter that corresponds with an inner contour of the joining interface of the outboard blade section.
  • the fiber mats may comprise, for example, glass fibers, carbon fibers, aramid fibers and/or natural fibers.
  • the upper and lower material layup may form together a shell region of the joining adapter.
  • the mandrel allows a precise forming of the upper material layup and is of high importance in the method for joining an outboard blade section to an inboard blade section of a longitudinally split wind turbine blade carried out using the joining adapter as it supports the joining adapter during the infusion with resin and during curing so that the mandrel acts as an inner mold.
  • the at least one mandrel can be an expandable mandrel that is expandable at least in the radial direction, wherein the expandable mandrel is arranged on the packing table in a non-expanded condition in step c).
  • the expandable mandrel can comprise suitable mechanical, hydraulic, pneumatic and/or electrical means that allow for a variation of at least one measure in the radial direction.
  • a cross section of the mandrel can be varied by actuators that change the height and/or the width of the mandrel.
  • the mandrel might comprise multiple segments that are relatively moveable to achieve said variation of its cross section. Between at least two mandrel segments there might be at least one gap, in particular extending in the longitudinal direction.
  • an expandable mandrel has the specific advantage that the joining adapter can be produced on the packing table with a smaller diameter than the diameter of the joining interfaces of the inboard and outboard blade sections to be joined so that it can be easier inserted thereto as there is a larger radial gap available.
  • the expandable mandrel is expanded so that the upper and lower material layup of the joining adapter abut against the respective joining interfaces of the blade sections to be joined.
  • two separate mandrels are arranged on the packing table, wherein in particular a first mandrel is associated with a leading edge side of the wind turbine blade and a second mandrel is associated with a trailing edge side of the wind turbine blade.
  • Both mandrels can be expandable mandrels in particular. Between the two mandrels there might be a gap that is adapted to receive a portion of a shear web.
  • the method may comprise step b1) arranging a shear web on the lower material layup and connecting it to the lower material layup with a first web joint, and further step e1) connecting the shear web to the upper material layup with a second web joint.
  • Step b1) can be in particular executed after step a) and before step b) and step e1) can be in particular executed after or during step e) and before step f).
  • a shear web is a component of a wind turbine blade that connects the blade shells of the pressure side and the suction side in the interior cavity of the blade and provides shear strength to the blade.
  • the joining adapter produced with the method according to the invention can comprise a portion of a shear web that complements the shear webs of the blade portions to be joined in the joining zone.
  • the lower and/or the upper material layup may comprise fibers in dry condition.
  • the shear web, the first web joint and/or the second web joint may comprise fibers in a pre-cast condition.
  • the dry fibers of the lower and/or upper material layup - in particular in the shell region of the joining adapter - are infused with a curable resin in the method for joining an outboard blade section to an inboard blade section of a longitudinally split wind turbine blade in which the joining adapter is to be used.
  • step a) and/or step e) may comprise placing at least one layer of a core material between the fiber mats.
  • Suitable core materials include low density foams and/or balsa wood.
  • the core material allows to reduce the weight of the final fiber-reinforced resin laminate while maintaining a sufficient rigidity and/or strength of the joining adapter as soon it is in place between the two blade sections to be joined with it.
  • a further embodiment of the method may comprise before step a) a step a1) arranging at least one tensioning strap in the at least one groove of the packing table. Additionally step f) may comprise extending the at least one tensioning strap over the upper material layup provided on the mandrel, connecting free ends of the tensioning strap and tensioning the tensioning strap to secure the lower and upper material layup against the mandrel.
  • the material layup By strapping the upper and lower material layup to the mandrel, the material layup can be secured to the mandrel when lifting the mandrel with the fiber layup fixed to it from the packing table and while arranging the mandrel inside the blade sections to be joined.
  • the packing table 1 is shown in Fig. 1 in an isometric view.
  • the packing table 1 is adapted for the manufacturing of a joining adapter 2 (see Fig. 3 ) to be used in a method for joining an outboard blade section 32 to an inboard blade section 31 (see Fig. 4 ) of a longitudinally split wind turbine blade in a joining zone 3 (see Fig. 4 ).
  • the packing table 1 comprises a three dimensionally shaped material layup surface 11 that has a shape that corresponds to an inner contour of respective joining interfaces 311,321 of the blade sections 31,32 to be joined (see Fig. 4 ).
  • the packing table comprises a center plane C oriented normally with respect to a longitudinal axis L.
  • the longitudinal axis of the wind turbine blade L falls together with the axial direction L of the packing table 1.
  • the center plane C corresponds to a center of the joining zone 3 in that the two blade sections 31,32 are joined together (see Fig. 4, 5 ).
  • the shape of an inboard portion 111 of the material layup surface 11 corresponds with an inner contour of the joining interface 311 of the inboard blade section 31 and the shape of an outboard portion 112 of the material layup surface 11 corresponds with an inner contour of the joining interface 321 of the outboard blade section 32.
  • the center plane C is located axially between the inboard portion 111 and the outboard portion 112.
  • the material layup surface 11 of the packing table 1 represents a negative form of the joining interfaces 311,321 of the blade sections 31,32 to be joined with the joining adapter 2.
  • the packing table 1 comprises a multitude of plates 14a,14b,14c stacked in the axial direction, for example 15-30 plates, in particular 22 plates, wherein each plate 14a,14b,14c comprises a portion of the material layup surface 11 so that the material layup surface 11 is provided by a totality of the stacked plates 14a,14b,14c.
  • This modular design is beneficial as it facilitates the three dimensional machining of the material layup surface 11.
  • the individual plates 14a,14b,14c may be held together by suitable clamping means, for example tie rods, cables or ropes.
  • the packing table 1 acts as a kind of lower mold, however it is not a mold in the strict sense as it is not used for infusing the material layup provided on it with a curable resin.
  • the material layup placed on top of the material layup surface 11 is a dry material layup that is only cast, respectively infused with a curable resin, when the joining adapter is used in the method for joining an outboard blade section to an in-board blade section of a longitudinally split wind turbine blade in a joining zone.
  • the packing table 1 is an important tool in the production method of a joining adapter 2 as it gives the (lower) material layup a close-to-final shape already before the casting of the material layup inside of the blade sections to be joined.
  • the packing table 1 has multiple grooves 12a,12b,12c in the material layup surface 11 that extend in a circumferential direction and that are provided with a predefined axial spacing there between.
  • Each of the grooves 12a,12b,12c is adapted to receive a tensioning strap (not shown) therein.
  • the tensioning straps may be arranged in the grooves 12a,12b,12c as the first step of a method for manufacturing of a joining adapter 2, i.e. already before first layers of the material layup are placed on the material layup surface.
  • the grooves 12a,12b,12c may - for example - be milled into a material of the packing table 1 or provided therein otherwise.
  • the grooves 12a,12b,12c are in particular provided at axial positions that correspond to the position of separation planes between neighboring plates 14a,14b,14c.
  • the tensioning straps (not shown) are used to secure a lower material layup provided on the material layup surface 11 and an upper layup provided on a mandrel against the mandrel.
  • the packing table 1 and/or the stacked plates 14a,14b,14c comprises a closed cell foam, in particular expanded polystyrene, that provides the three dimensionally shaped material layup surface 11.
  • the plastic material may be in particular coated with a relatively harder surface coating, for example comprising a polyurethane which renders the material layup surface 11 more robust.
  • the packing table 1 comprises two sidewalls 13a,13b forming a half-pipe shaped portion of the material layup surface 11.
  • the half-pipe shaped portion of the material layup surface 11 is located both in the inboard portion 111 and the outboard portion 112 of the material layup surface 11, wherein the center place C divides the half-pipe shaped portion into an inboard half-pipe and an outboard half-pipe.
  • layup material e.g. fiber mats and/or core materials
  • Opposing axial end sections 15 of the packing table 1 are sidewall-free so that the material layup surface 11 is essentially flat there.
  • the axial end sections 15 are used to create a material layup that corresponds to non-circumferential portions of the joining adapter 2 such as a shear web and/or other reinforcement beams associated with the leading and/or the trailing edge of the wind turbine blade.
  • Fig. 2 shows a longitudinal sectional view of the packing table 1 along the center axis.
  • the (lower) material layup 21 is shown on top of the material layup surface 11 .
  • Inside of the (lower) material layup 21 at least one layer of core material 22 is provided.
  • the shape of the material layup surface 11 in the outboard portion 112 provides the outer contour 212 of the joining adapter 2 for the joining interface of the outboard blade section.
  • the shape of the material layup surface 11 in the inboard portion 111 provides the outer contour 212 of the joining adapter 2 for the joining interface of the inboard blade section.
  • the inner contour 211 of the joining adapter 2 complements the inner contour of the inboard and outboard blade sections after joining so that the inner contour 211 of the joining adapter 2 can be understood as to equal to the inner contour of the wind turbine blade in the joining zone 3 (see Fig. 4 ).
  • material layup surface 11 comprises at least two tapering sections with the center plane C in between.
  • the tapering sections taper axially outwardly from the center plane C in opposing axial directions so that the thickness of the joining adapter decreases with axial distance from the center plane C.
  • a first tapering section is located in the inboard portion 111 of and a second tapering section is located in the outboard portion 112 so that the joining adapter 2 produced with the packing table 1 comprises two outwardly tapering ends that correspond to inversely tapering sections in the joining interfaces 311,321 of the blade sections 31,32 (see Fig. 4 ) to be joined with the joining adapter 2.
  • Fig. 3 shows a longitudinal sectional view of a shell region of a joining adapter 2 produced with the packing table 1. The shear web and reinforcement beams are not shown.
  • Fig. 4 shows a longitudinal sectional view of the joining zone 3 between two blade sections 31,32 to be joined.
  • Both the joining interface 311 of the inboard blade section 31 and the joining interface 321 of the outboard blade section 32 comprise outwardly tapering sections that mate with the two tapering ends of the joining adapter 2.
  • the tapering sections of the joining interfaces 311,321 form a recess in that the joining adapter can be arranged.
  • Fig. 5 shows the joining zone 3 with the joining adapter 2 in place.
  • a mandrel tool 4 having two separate mandrels 41, 42 is arranged on the packing table 1.
  • the (lower) material layup to be provided in a material layup gap M between the material layup surface 11 and the mandrel tool 4 is not shown.
  • Both mandrels 41,42 are expandable mandrels and can be expanded in the radial direction by varying at least one dimension in the height and/or width direction. While the lower material layup is provided on the material layup surface 11 of the packing table 1 an upper material layup of the joining adapter 2 is provided on top of the mandrel tool 4.
  • the mandrel tool 4 is placed on the packing table, i.e.
  • the mandrel tool 4 is in its non-expanded condition so that the dimensions of the prepacked joining adapter 2 are smaller than the dimensions of the respective joining interfaces 311, 321 of the blade sections 31,32 to be joined. This facilitates insertion of the joining adapter into the joining interfaces 311, 321 of the blade sections.
  • the mandrel tool 4 is only expanded after it has been moved to its final joining position in the joining zone 3 between the two blade sections 31,32. Between the two mandrels 41,42 a gap 43 is provided in that a material layup for a shear web and/or excess material can be arranged.
  • Fig. 7 shows a flow chart of a first embodiment of the method for manufacturing of a joining adapter 2 to be used in a method for joining an outboard blade section 32 to an inboard blade section 31 of a longitudinally split wind turbine blade in a joining zone 3, using a packing table 1 according to the invention.
  • the method comprises the following steps:
  • Fig. 8 shows a flow chart of a second embodiment of the method for manufacturing of a joining adapter. It comprises a step a1) arranging at least one tensioning strap in the at least one groove 12a,12b,12c of the packing table 1 that is executed before step a) of the method of the first embodiment.
  • step f) comprises extending the at least one tensioning strap over the upper material layup provided on the mandrel 4,41,42, connecting free ends of the tensioning strap and tensioning the tensioning strap to secure the lower material layup 21 and upper material layup against the mandrel 4,41,42.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Manufacturing & Machinery (AREA)
  • Moulding By Coating Moulds (AREA)
EP23170528.6A 2023-04-28 2023-04-28 Table d'emballage pour la fabrication d'un adaptateur d'assemblage utilisé dans un procédé d'assemblage Pending EP4454852A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP23170528.6A EP4454852A1 (fr) 2023-04-28 2023-04-28 Table d'emballage pour la fabrication d'un adaptateur d'assemblage utilisé dans un procédé d'assemblage
PCT/EP2024/058336 WO2024223204A1 (fr) 2023-04-28 2024-03-27 Table d'emballage pour la fabrication d'un adaptateur d'assemblage à utiliser dans un procédé d'assemblage d'une section de pale extérieure à une section de pale intérieure d'une pale d'éolienne divisée longitudinalement et procédé de fabrication d'un adaptateur d'assemblage

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP23170528.6A EP4454852A1 (fr) 2023-04-28 2023-04-28 Table d'emballage pour la fabrication d'un adaptateur d'assemblage utilisé dans un procédé d'assemblage

Publications (1)

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EP4454852A1 true EP4454852A1 (fr) 2024-10-30

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EP (1) EP4454852A1 (fr)
WO (1) WO2024223204A1 (fr)

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2012149939A2 (fr) * 2011-05-04 2012-11-08 Vestas Wind Systems A/S Procédé de préparation d'un stratifié composite
EP2591230B1 (fr) * 2010-07-08 2017-06-14 Blade Dynamics Limited Aube de turbine éolienne
WO2017171704A1 (fr) * 2016-03-28 2017-10-05 General Electric Company Ensemble moule d'extrémité de pale de rotor comprenant des vessies dilatables et procédé de formation d'extrémité de pale de rotor
WO2020244902A1 (fr) 2019-06-07 2020-12-10 Siemens Gamesa Renewable Energy A/S Méthode de fabrication d'une pale d'éolienne et pale d'éolienne
US20210060886A1 (en) * 2019-08-29 2021-03-04 Bell Textron Inc. Co-Cured Multi-Piece Tubular Composite Body
WO2021073842A1 (fr) 2019-10-18 2021-04-22 Siemens Gamesa Renewable Energy A/S Méthode et système d'assemblage de parties de pale d'une pale d'éolienne
EP3885112A1 (fr) * 2020-03-27 2021-09-29 Siemens Gamesa Renewable Energy A/S Procédé et moule de fabrication d'une pale d'éolienne
US11305503B2 (en) * 2016-12-22 2022-04-19 Wobben Properties Gmbh Method for producing a wind turbine rotor blade, and wind turbine rotor blade
US20220143874A1 (en) * 2019-03-05 2022-05-12 Lm Wind Power A/S A gripping device for lifting a preform for a wind turbine blade

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2591230B1 (fr) * 2010-07-08 2017-06-14 Blade Dynamics Limited Aube de turbine éolienne
WO2012149939A2 (fr) * 2011-05-04 2012-11-08 Vestas Wind Systems A/S Procédé de préparation d'un stratifié composite
WO2017171704A1 (fr) * 2016-03-28 2017-10-05 General Electric Company Ensemble moule d'extrémité de pale de rotor comprenant des vessies dilatables et procédé de formation d'extrémité de pale de rotor
US11305503B2 (en) * 2016-12-22 2022-04-19 Wobben Properties Gmbh Method for producing a wind turbine rotor blade, and wind turbine rotor blade
US20220143874A1 (en) * 2019-03-05 2022-05-12 Lm Wind Power A/S A gripping device for lifting a preform for a wind turbine blade
WO2020244902A1 (fr) 2019-06-07 2020-12-10 Siemens Gamesa Renewable Energy A/S Méthode de fabrication d'une pale d'éolienne et pale d'éolienne
US20210060886A1 (en) * 2019-08-29 2021-03-04 Bell Textron Inc. Co-Cured Multi-Piece Tubular Composite Body
WO2021073842A1 (fr) 2019-10-18 2021-04-22 Siemens Gamesa Renewable Energy A/S Méthode et système d'assemblage de parties de pale d'une pale d'éolienne
EP3885112A1 (fr) * 2020-03-27 2021-09-29 Siemens Gamesa Renewable Energy A/S Procédé et moule de fabrication d'une pale d'éolienne

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